Method and apparatus for multi-stage air treatment system

ABSTRACT

Method and apparatus for treating air containing hydrogen sulfide gas, volatile organic compounds, heavy metals and other mercaptans in order to reduce odor and corrosion related to wet wells, dry pits, grease traps and the like. The system comprises a first and second stage air treatment system. A vacuum pump in the primary (stage  2 ) treatment housing vacuums the contaminated air from the source and pumps the air through a set of diffusers into a treatment fluid wherein the air is then passed through a pair of porous plates and upward through a discharge pump and then into the atmosphere. Prior to treating the air in the primary housing, it is treated in a pretreatment dry air filter wherein the air is inlet into the pretreatment (stage  1 ) housing and then through a microfilter prior to being passed into the primary housing for further treatment.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to air treatment and, moreparticularly, is concerned with multi-stage system for removing odorfrom sewage treatment related devices.

2. Description of the Prior Art

Air treatment devices have been described in the prior art, however,none of the prior art devices disclose the unique features of thepresent invention. In U.S. Pat. No. 6,616,733 dated Sep. 9, 2003,Pellegrin disclosed a method and means for filtering an air stream withaqueous froth. In U.S. Pat. No. 7,588,627 dated Sep. 15, 2009, Kijlstra,et al., disclosed a process for the removal of hydrogen sulfide andmercaptans from a gas stream. In U.S. Pat. No. 6,350,302 dated Feb. 26,2002, Hallstead, Sr., disclosed an air filtration system. In U.S. Pat.No. 6,083,307 dated Jul. 4, 2000, Dular disclosed a water filter kit fordrywall dust control. In U.S. Pat. No. 5,858,072 dated Jan. 12, 1999,Motoda disclosed a gas suction filtration apparatus. In U.S. Pat. No.5,261,933 dated Nov. 16, 1993, Greene disclosed a vent gas deodorizingsystem. In U.S. Pat. No. 3,856,487 dated Dec. 24, 1974, Perez discloseda gas scrubber. While these air treatment devices may be suitable forthe purposes for which they were designed, they would not be as suitablefor the purposes of the present invention as hereinafter described.

SUMMARY OF THE PRESENT INVENTION

The present invention discloses a method and apparatus for treating aircontaining hydrogen sulfide gas, volatile organic compounds, heavymetals and other mercaptans in order to reduce odor and corrosionrelated to wet wells, dry pits, grease traps and the like. The presentinvention comprises a first and second stage air treatment system. Avacuum pump in the primary (stage 2) treatment housing vacuums thecontaminated air from the source and pumps the air through a set ofdiffusers into a treatment fluid wherein the air is then passed througha pair of porous plates and upward through a discharge pump and theninto the atmosphere. Prior to treating the air in the primary housing,it is treated in a pretreatment dry air filter wherein the air is inletinto the pretreatment (stage 1) housing and then through a microfilterprior to being passed into the primary housing for further treatment.

An object of the present invention is to remove undesirable compoundsfrom the air of wet wells, dry pits, grease traps and the like. Afurther object of the present invention is to reduce the odor of the airtreatment stream. A further object of the present invention is toprovide a non-toxic discharge comprising treated air. A further objectof the present invention is to provide a means for air treatment whichcan be easily operated by a user. A further object of the presentinvention is to provide an air treatment system which can be relativelyinexpensively manufactured.

The foregoing and other objects and advantages will appear from thedescription to follow. In the description reference is made to theaccompanying drawings, which form a part hereof, and in which is shownby way of illustration specific embodiments in which the invention maybe practiced. These embodiments will be described in sufficient detailto enable those skilled in the art to practice the invention, and it isto be understood that other embodiments may be utilized and thatstructural changes may be made without departing from the scope of theinvention. In the accompanying drawings, like reference charactersdesignate the same or similar parts throughout the several views.

The following detailed description is, therefore, not to be taken in alimiting sense, and the scope of the present invention is best definedby the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more fully understood, it will now bedescribed, by way of example, with reference to the accompanyingdrawings in which:

FIG. 1 is a cross sectional view of the present invention.

FIG. 2 is an environmental view of the present invention.

FIG. 3 is a perspective view of a portion of the present invention.

FIG. 4 is a perspective view with cut-away portions of the presentinvention.

FIG. 5 is a perspective view of a portion of the present invention.

LIST OF REFERENCE NUMERALS

With regard to reference numerals used, the following numbering is usedthroughout the drawings.

10 present invention 12 stage 1 filter 14 stage 2 filter 16 enclosure 18inlet nozzle 19 inlet 20 outlet 22 direction arrow 24 discharge pipe 26slot 28 microfilter 30 microfilter 32 inlet 34 compartment 36compartment 38 outlet 40 enclosure 42 lower compartment 44 treatmentfluid 46 upper compartment 48 plate 50 plate 52 slots 54 vacuum motor 56direction arrows 58 air diffuser 60 distribution pipe 62 diffuser slots64 drain pipe 66 control valve 68 air vent 70 control valve 72 vacuumrelief valve 74 inlet 76 outlet 78 arrows 80 ground 82 wet well 84 cover86 septic fluid 88 froth 90 drop 92 deflector plate 94 plate 96 aperture

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following discussion describes in detail at least one embodiment ofthe present invention. This discussion should not be construed, however,as limiting the present invention to the particular embodimentsdescribed herein since practitioners skilled in the art will recognizenumerous other embodiments as well. For a definition of the completescope of the invention the reader is directed to the appended claims.FIGS. 1-5 illustrate the present invention wherein a method andapparatus for treating air is disclosed.

Turning to FIGS. 1-5, therein is shown the present invention beinggenerally shown at 10 comprising a Stage 1 dry filtration system 12 anda Stage 2 wet filtration system 14. The Stage 1 filtration system 12comprises an enclosure or housing 16 having an air inlet nozzle 18leading into an inlet conduit 19 and an outlet 20 wherein the inner aircirculation pattern is shown at arrows 22 and having a first micro airfilter 28 and a second micro air filter 30 internal housing 16 so thatair passes through the microfilter 28, 30 and then out a verticallydisposed central discharge pipe 24 comprising a centrally disposedslotted air conveyance pipe 24 having a plurality of entry slots 26therein and then into the outlet conduit 20 of the enclosure 16 and intothe inlet conduit 32 of the Stage 2 filtration system 14. Arrows 78illustrate the contaminated airstream containing odorous vapors enteringinlet 18. Note that the Stage 1 filter has a first upper compartment 34containing the microfilter 28, 30 and a second lower compartment 36containing the outlet 20 so that the two compartments are kept separatefrom each other in order to improve sanitary conditions. The Stage 2filter system has an inlet 32 along with an outlet conduit 38 comprisingan enclosure or housing 40 having a lower compartment 42 containing atreatment fluid 44 therein and an upper compartment 46 containing firstplate 48 and second plate 50 each having a plurality of holes/slots 52therein, wherein the slots are oriented toward the outer portion of theplates 48, 50 with the center portion being solid, wherein a vacuumblower motor 54 provides means for inducing air flow through the Stage 1and 2 systems and then out an outlet pipe 38 wherein a plurality ofarrows 56 show the air flow through the Stage 2 filter system. Alsoshown is a solid deflector plate 92 which routes airflow outwardly andthen immediately above plate 92 is plate 94 having a plurality of slots52 disposed toward its center portion and being solid toward its outerportion. The unique orientation and arrangement of slots and solidportions of plates 48, 50, 92 and 94 create a winding path for theairflow which assures complete mixing, volitization of fluid in theairstream, an effectively dry airstream at outlet 38, and increasesresidence time of housing 40. Other features of the Stage 2 systeminclude a stacked plurality of inner diffusers 58 having a central airdistribution pipe or conduit 60 wherein the air passes through thediffusers and out a plurality of slots 62 into the treatment fluid 44,through the plates 50, through the upper compartment 46, through themotor driven vacuum pump 54 and then out the outlet pipe 38. Also shownis a drain outlet 64 having a control valve 66 thereon along with an airvent 68 having a control valve 70 thereon and a vacuum relief valve 72in order to prevent the housing 40 from collapsing in the event theinlet pipe 32 becomes clogged. The vacuum relief valve has an inlet 74and an outlet 76.

Regarding plate 92, this is a solid plate designed to deflect theairflow and fluid outwardly and away from the center of the tank 40.There are no holes or slots in this plate. When the air is released fromfluid 44 it cause a bubbling action and plate 92 prevents it fromhitting the next full plate 94 with the central air slots 52. Plate 94also has an aperture 96 in its center to accommodate pipe 60. A purposeof plate 92 is to prevent excessive bubble build up in the lower portionof the tank 40.

FIG. 2 also shows an exemplary under the ground 80 wet well 82 withcover 84 containing a septic fluid 86 which emits sewage odors or thelike. An inlet nozzle 18 is attached to one end of a non-corrosive EDPMhose 19 and inserted into the contaminated air space 82 where it drawsthe toxic air outwardly as a part of the airstream. The other end of thehose leads into the Stage 1 filter. A micro diffuser 58 is located inthe lower compartment 42 of the tank 40. This micro diffuser 58 issubmerged in a concentrated organic solution 44 used to neutralize andremove volatile organic compounds, hydrogen sulfide gas, all othermercaptans, and heavy metals upon contact.

Regarding the diffusers 58, one diffuser will lay flat on the bottom ofthe tank 40 and will contain air discharge slot openings 62 of 0.006inch (all measurements are in inches) and the 2nd one will contain airslots opening of 0.004 and the top diffuser will have air slot openingsof 0.002. These diffusers are located about 1 inch apart. This willprovide a Multi Stage Micro Diffuser 58 that is critical in breakingdown and separating the various sewer gases. When these gases areexposed to a vacuum, (negative pressure) they are easily separated dueto their various densities, making their molecular structure accessiblefor our chemical solution to penetrate and destroy the toxic sewergases. There is a unique chemical reaction that takes place when youcombine the specific gravity of the treatment fluid and thevacuum/negative pressure environment that is created in the gasextractor. Plates 48, 50 are located 4 inches apart and each plate willcontain air slot openings 52 of 0.002-0.004. This will allow a retentiontime of 0.75 seconds required before the treated gases are releasedeither back into the atmosphere or the lift station where they wereextracted from originally. Air slot openings 26 (0.003) to the Stage Idry air separator 12 is where the toxic gas separation actually starts.This will provide one long micro 24 diffuser inside the canister 16.Plate 94 and its slots 52 are similar to plates 48, 50.

Also shown is a 2 hp regenerative blower 54 and a vacuum relief valve72. The vacuum relief valve 72 is a critical component to keep the tank40 from imploding in the event the air intake/stage 1 dry air filter 12becomes clogged up.

The treatment fluid 44 is an aqueous solution comprising a clear,colorless organic liquid having a ph of about 10 and a boiling pointranging from 212-370 degrees Fahrenheit.

The present invention 10 is a fully self-contained, non-corrosive,multi-chambered, energy efficient, non-hazardous, organic and all greendevice created to extract, process instantly upon contact, toxic gasessuch as hydrogen sulfide, volatile organic compounds (VOC's), heavymetals and all other mercaptans which occur naturally in wet wells 82,dry pits, grease traps and the like. The toxic gases are pulled from thewet well 82, dry pit, or grease trap through specifically designednon-corrosive micro diffusers (Stage 1 and 2 at 12, 14) which help breakdown the toxic gases.

Immediately above the concentrated solution of treatment fluid 44 aremulti layers of slotted plates 48, 52, 94 designed to help remove VOC'sand hydrogen sulfide gas. The contaminated air is pulled from the wellby placing a vacuum on the tank 40. As the vacuum is created,contaminated air is pulled from the air space of the wet well/dry pit orgrease trap 82 through the two micro diffusers (Stage 1 and 2 at 12, 14)and through the concentrated solution of treatment fluid 44 where up to80% of all the VOC's and hydrogen sulfide gas, other mercaptans andheavy metals are instantly removed. As the toxic air travels through themicro diffuser 58 submerged in the concentrated solution 44 agitationoccurs. This agitation causes micro foaming froth 88 to accumulate onthe plates 48, 50, 94 of the tank and to drop or drip 90 therefrom. Asthe vacuum occurs in the tank, this pulls the highly concentratedsupercharged foam and froth up onto the plates 48, 50. As the plates 48,50 become saturated and coated with the supercharged micro-fine bubblescreated by the agitation in the bottom 42 of the tank, the remainingVOC's, hydrogen sulfide gas, mercaptans and heavy metals aresubstantially neutralized and removed as they pass through thesaturation chambers. This process is fast and irreversible in the stateof the process. Final discharge is substantially clean, organicallyprocessed air.

This process of extracting and removing toxic gases instantly and oncontact is accomplished by using a unique combination of supercharged,micro-foaming, micro diffusers, fluid pressure in a confined space and aregulated vacuum pressure, simultaneously in a multi chambered air tighttank. This makes the present invention a cost-effective closed loop oropen loop odor control and toxic gas removal process for wet wells, drypits and grease traps.

The present invention reduces hydrogen sulfide gas by up to 95%, reducesodor by up to 95%, is an all organic solution, non-hazardous discharge,reduces B.O.D. and C.O.D., retention time >2 seconds (instantaneous andirreversible), water soluble solution, non-toxic discharge, all greenconstruction, fully self contained, no moving parts, 99% maintenancefree, super energy efficient, installs in 5 minutes, no retro fittingrequired, no wiring required (plug into 120 volt outlet), concentratedsolution—non DOT regulated, concentrated solution—ships UPS,concentrated solution lasts 90 to 120 days, and the disposal method isto empty used solution into wet well/dry pit or grease trap.

I claim:
 1. An apparatus for removing odor from a contaminated airstreamfrom a wet well, comprising: a) a first housing, a first inlet disposedon said first housing for inletting the airstream into said firsthousing, a first outlet disposed on said first housing for dischargingthe airstream from said first housing; b) a filter disposed in saidfirst housing for filtering the airstream, said filter being a dryfilter, wherein said filter is disposed internal said first housing sothat the airstream passes through said filter between said first inletand said first outlet; c) a second housing, a second inlet and a secondoutlet disposed on said second housing, wherein said first outlet isconnected to said second inlet so that said second housing receives theairstream from said first housing; d) a first and second compartmentdisposed in said second housing, said second compartment disposed abovesaid first compartment, said second inlet disposed on said firstcompartment so that the airstream enters said first compartment and saidsecond outlet disposed on said second compartment so that the airstreamis discharged from said second compartment; e) a treatment fluid forremoving odor from the airstream, wherein said treatment fluid isdisposed in said first compartment; f) a plurality of diffusers disposedunder a surface of said treatment fluid, wherein said second inletconnects to said diffusers so that the airstream passes through saiddiffusers and into said treatment fluid so that odor is removed from theairstream, wherein froth is generated as the airstream passes throughsaid treatment fluid; g) at least one plate disposed between said firstcompartment and said second compartment so that said plate is above saidsurface of said treatment fluid, said plate having a plurality of holestherein, wherein said froth is captured on said plate so that said frothis removed from the airstream; and, h) a vacuum pump disposed in saidsecond housing for vacuuming the airstream through the apparatus so thatthe airstream is conveyed from said first inlet to said second outlet,wherein odors are substantially removed from the airstream.
 2. Theapparatus of claim 1, said diffusers having a plurality of air dischargeopenings therein, wherein said openings range in size from 0.002 inch to0.006 inch in diameter.
 3. The apparatus of claim 1, wherein there arethree diffusers disposed in a vertically spaced apart manner so that oneis above the other.
 4. The apparatus of claim 1, said plate having aplurality of slots therein, wherein said slots range in size from 0.002inch to 0.004 inch in width.
 5. The apparatus of claim 1, wherein saidtreatment fluid is an organic aqueous solution for removing hydrogensulfide from the airstream.
 6. The apparatus of claim 1, furthercomprising a first, second and third plate disposed between said firstcompartment and said second compartment so that said first, second andthird plate is above said surface of said treatment fluid, said firstplate being a solid plate so as to divert airflow outwardly, said secondplate having holes disposed toward its center portion so that its outerportion is solid, and said third plate having holes disposed toward itsouter portion so that its center portion is solid, wherein the airstreamtravels in a winding path as the airstream is conveyed from said firstinlet to said second outlet.